A method of additive forming of a 3D object by layering solid base blocks (3) comprises the following steps: a. arranging at least one guiding element (2) oriented in the direction of forming of the 3D object; b. depositing a first layer comprising at least one solid base block (3) in the horizon of the first layer; c. depositing at least one further layer comprising at least one solid base block (3) at a horizon spatially spaced from the horizon of the first layer in the direction of forming the 3D object;
while at least one base block (3) of the at least one layer is arranged in the region of the at least one guiding element (2) and is arranged with at least one cooperating means (4), cooperating with the said at least one guiding element (2).

3D object can also contain various solid base blocks (3). It is advantageous if the first layer is arranged on the base plate (1). It is advantageous if at least one base block (3) is arranged with a fastening means (5), for example an adhesive. It is advantageous if, after step c), the base plate (1) and/or the at least one guiding elements (2) are removed. The 3D object can be strengthened by a thermal process.

A method of additive forming of a 3D object by layering solid base blocks (3) comprises the following steps: a. arranging at least one guiding element (2) oriented in the direction of forming of the 3D object; b. depositing a first layer comprising at least one solid base block (3) in the horizon of the first layer; c. depositing at least one further layer comprising at least one solid base block (3) at a horizon spatially spaced from the horizon of the first layer in the direction of forming the 3D object;
while at least one base block (3) of the at least one layer is arranged in the region of the at least one guiding element (2) and is arranged with at least one cooperating means (4), cooperating with the said at least one guiding element (2).

3D object can also contain various solid base blocks (3). It is advantageous if the first layer is arranged on the base plate (1). It is advantageous if at least one base block (3) is arranged with a fastening means (5), for example an adhesive. It is advantageous if, after step c), the base plate (1) and/or the at least one guiding elements (2) are removed. The 3D object can be strengthened by a thermal process.

Copolymers of condensation polymers are formed by a method of cleaving and reacting with a chain extender to form an end capped cleaved condensation polymer that is further reacted with a second compound that may be comprised of a further chain extender and condensation polymer that react with a reactive group still remaining in the chain extender capping the cleaved condensation polymer. The method allows the formation of block copolymers, branched copolymers and star polymers of differing condensation polymers bonded through the residue of a chain extender.

In the case of a method for producing a three-dimensional shaped object by means of layer-by-layer material application, a base surface for holding the three-dimensional shaped object, a liquid, flowable or powder-form first material that can solidify, a powder-form second material including thermoplastic powder particles, and a solvent are made available. From the first material, a negative mold layer having a cavity for a shaped-object layer to be produced is produced and solidified. The bottom of the cavity is charged to an electric potential having a first polarity, and the powder particles are charged to a potential having a second polarity. The powder particles are applied to a support surface that is positioned relative to the cavity in such a manner that the powder particles are transferred from the support surface into the cavity and form a shaped-object layer having a positive shape that matches the negative mold in this cavity. The shaped-object layer is sintered by means of the effect of heat. A planar surface is produced by means of material removal, which surface extends over the negative mold layer and the shaped-object layer. The above steps are repeated at least once. Afterward the negative mold layers are dissolved in the solvent.

A functional polymeric cutting edge structure and methods for the manufacturing of cutting edge structures comprised of polymeric materials are provided. The cutting edge structures may be produced on a substrate having a blade body or blade support type. The polymeric material is produced by curing a precursor material activated by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to activate the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.

Systems and methods of additively manufacturing leak resistant objects are disclosed. Provided herein are methods of forming objects having walls and/or surfaces that are resistant to leaks. Objects disclosed are formed from or manufactured from compositions, including metals, polymers, and combinations thereof. Objects provided herein are made from methods of forming individual shells, forming of series shells, and layer-by-layer forming of objects. Further disclosed are methods of interconnecting shells, layers, and processes for transitioning therebetween the shells and layers.

An apparatus and a process for manufacturing a three-dimensional object by successive layer-by-layer consolidation of selected zones of a powder stratum, the consolidated zones corresponding to successive sections of the three-dimensional object, each layer being divided into a central internal portion and an external border, said process comprising the following steps in order: a—depositing a powder layer on a holder; b—fusing the external border of said powder layer by means of a laser beam originating from a first energy source by moving the laser beam of said first energy source relative to the object along a preset path that follows the contour of said external border corresponding to the contour of the cross section of the object so as to selectively fuse said layer; and c—fusing the central internal portion of the powder layer by means of an electron beam originating from a second energy source, by moving the electron beam of said second energy source relative to the object so as to sweep it over said central internal portion along a preset path corresponding to the central internal portion of the cross section of the object so as to selectively fuse said layer; or d—repeating steps a and b N times so as to form a plurality of superposed layers of fused material forming a portion of the external border of said object and then carrying out step c so as to fuse the central internal portion of the object corresponding to the N powder layers; and e—repeating steps a to c or a, b and d until all the layers of the object have been consolidated.

An apparatus and a process for manufacturing a three-dimensional object by successive layer-by-layer consolidation of selected zones of a powder stratum, the consolidated zones corresponding to successive sections of the three-dimensional object, each layer being divided into a central internal portion and an external border, said process comprising the following steps in order: a—depositing a powder layer on a holder; b—fusing the external border of said powder layer by means of a laser beam originating from a first energy source by moving the laser beam of said first energy source relative to the object along a preset path that follows the contour of said external border corresponding to the contour of the cross section of the object so as to selectively fuse said layer; and c—fusing the central internal portion of the powder layer by means of an electron beam originating from a second energy source, by moving the electron beam of said second energy source relative to the object so as to sweep it over said central internal portion along a preset path corresponding to the central internal portion of the cross section of the object so as to selectively fuse said layer; or d—repeating steps a and b N times so as to form a plurality of superposed layers of fused material forming a portion of the external border of said object and then carrying out step c so as to fuse the central internal portion of the object corresponding to the N powder layers; and e—repeating steps a to c or a, b and d until all the layers of the object have been consolidated.

An exemplary optical projection method and system is disclosed, e.g., femtosecond projection two-photon lithography (FP-TPL) based operation, that applies multiple temporally focused light with reduced density of the projected mask to control over-polymerization defects (e.g., without need to tune the photopolymer composition) when certain aspect ratio of the submicron features are desired.

A polymer composition suitable for manufacturing of isotropic three-dimensional printed articles, the composition including: a matrix phase including a propylene-based polymer or copolymer; and a dispersed phase in the matrix phase, the dispersed phase including an ethylene-based copolymer having a C3-C12 comonomer, wherein the dispersed phase has a different composition than the matrix phase, wherein the matrix phase has a crystallization half-time of less than 60 minutes.